Some replacement parts ready to be painted

The replacement timing gear cover and injector pump drive gear cover. I opted to replace the injector pump drive gear cover with one that has a mount for a tachometer sensor, in case I decide to attempt to install a factory tach at some point. Both parts spent a lot of time in a parts washer (thanks again, Seth :) ); this is why they almost look brand-new. Both of these came off of a 6.9l that had an unknown amount of miles before suffering engine failure, and were in pretty bad shape when I removed them. Note that I have the part of the cover that the water pump and gasket mounts to taped off; this is so that paint won't get onto the gasket surface or into a place where it'll be immersed with coolant.

Special thanks again to Calvin (towcat) from TheDieselStop for giving me an opportunity to remove parts from the truck that I got these pieces from.

You can best see here the part of the timing gear cover that broke. To the right is the new timing gear cover; to the left is the timing gear cover that came off of my engine originally.

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Main Page

Introduction to the project

Before the project begins

Removing external parts and accessories

Removing cylinder heads

Heads, gaskets, and the block after head removal

Removing timing gear cover and camshaft

Cleaning the piston tops

Cleaning the ins and outs of the engine

Final engine block cleaning with compresed air

Oil cooler disassembled

Parts ready for painting

Final painting preparation

Parts after painting

Installing BajaGringo drains

Installing the camshaft

Re-installing the camshaft

Assembling and testing the oil cooler

First steps of modifications for the turbocharger

Comparing the stock head bolts to ARP studs (lengthy!)

Installing the cylinder heads

Installing the head studs

Installing the valvetrain

Installing the intake manifold and injector pump

Assembling and installing the turbocharger

Last touches on engine assembly

Installing radiator

The Finished Project